MNT Design 2520of 2520equipments

Production of Mononitrotoluene
CHAPTER 6
EQUIPMENT DESIGN
(A) DESIGN OF REACTOR:
1. PROCESS DESIGN:
The nitration of toluene is an important heterogeneous liquid-phase reaction. It is
generally considered that the function of the sulfuric acid is to maintain the nitric acid in
a dehydrated state as a result of its strong for water. If the nitration is carried out with
strong nitric acid alone the rate of reaction is rapid at the start but drops off quickly as the
water formed by the reaction dilutes the acid. This reduction in rate as the reaction
proceeds is greatly lessened by the presence of sulfuric acid or some other dehydrator.
Rates of mono nitration when mixed nitric and sulfuric acid is employed have been
measured by McKinley and White on toluene. The investigators made measurements in
continuous equipment under steady-state conditions with high degrees of agitation to
ensure distribution equilibrium.
Thermodynamic and experimental data indicate that the equilibrium constant is
very large for the nitration of aromatic under liquid- phase conditions. Accordingly the
reverse reaction may be neglected and the rate reaction equation below can be written as
follows if it is assumed that agitation is sufficient to approximate equilibrium distribution
between the phases. (Ref. 2)
r = k xAa Aa xBb Bb (Va + Vbk )
---------------------- ( 1 )
where k = ka KB
k= kb KA/ ka KB
Va = fractional volume of phase a
Suffix a - acid layer and
b - nitration product (organic phase)
A - nitric acid
B - Toluene
x Aa = mole fraction of HNO3 in acid phase.

x Bb = mole fraction of toluene in organic phase (nitration product)
50
Aa = activity coefficient of HNO3 in acid layer.

Bb = activity coefficient of toluene in nitration product
The overall reaction velocity constant k is a function of temperature, which may be
expressed by the Arrhenius equation.
ln k = - E / RT + A
---------------------- ( 2 )
In applying equation (1) the mutual solubility of the phases may be neglected and
x Aa is based on the total HNO3, H2SO4 and H2O content of the system while x Bb is based
on the total toluene plus nitrotoluene.
The data of McKinley and White indicate that for the mono nitration of the
toluene the activity coefficient of the toluene Bb may be taken as unity over a wide range
of conditions. It was also found that K
LQGLFDWLQJ WKDW WKH UHDFWLRQ WDNLQJ SODFH LQ WKH
organic phase is negligible. With these terms evaluated, rate data at a constant
temperature may be used for empirical evaluation of the relative activity coefficients of
the nitric acid Aa
With the assumption that the activity coefficients of Fig. 210 are independent of
temperature, the other constants of equation s (7) and (8) for the mono nitration of
benzene and toluene in the temperature range from 15 to 50 C are as follows:
Bb
1.0
E cal per g-mole
14,000
A (rates in g-mole per hr per liter of combined phases )
27.58
ln k = -E / RT + A
= -14000 / (1.987 x ( 273 + 35 ) ) + 27.58

= -22.876 + 27.58
k = 110.39 g mol/ hr lt
51
The following tables indicate the mole fractions of the various components in both the
inlet and outlet streams of the reactor:
Inlet to the reactor:
Mixed Acid:
Tons/day
Kg/hr
HNO3
13.094
545.58
8.66
5%
3.82 %
H2SO4
188.75
77864.58
80.251
72.13 %
35.43 %
H2O
59.381
2474.21
137.456
22.69 %
60.69 %
MNT
0.457
19.04
0.139
0.18 %
0.06 %
261.682
10903.41
226.506
100 %
100 %
TOTAL
Kgmol/hr Weight %
Mol %
Organic Phase:
Tons/day Kg/hr
Kgmol/hr Weight % Mol %
TOLUENE
18.105
754.38
8.1998
99 %
99.2 %
PARAFFIN
0.183
7.62
0.067
1%
0.8 %
TOTAL
18.288
762
8.2668
100 %
100 %
Assuming 97 % conversion in the reactor, the composition of mixed acid and organic
phases in the outlet stream are as follows.
Outlet from the reactor:

Acid Layer:
Tons/day Kg/hr
HNO3
0.585
24.383
0.387
0.23 %
0.17 %
H2SO4
188.696
7862.316
80.228
74.71 %
35.51 %
H2O
62.710
2612.916
145.162
24.83 %
64.24 %
MNT
0.585
24.384
0.178
0.23 %
0.08 %
252.570
10524
225.955
100 %
100 %
TOTAL
52
Nitration Product:
Tons/day Kg/hr
MNT
26.262
1094.25
7.987
96.51 %
94.20 %
NITRO CRESOL
0.293
12.192
0.080
1.08 %
0.94 %
TOLUENE
0.183
7.62
0.083
0.67 %
0.98 %
PARAFFINS
0.183
7.62
0.067
0.67 %
0.79 %
H2SO4
0.219
9.144
0.093
0.81 %
1.10 %
H2O
0.073
3.048
0.169
0.26 %
1.99 %
TOTAL
27.213
1133.874
8.479
100 %
100 %
From equation (1),
r = k x Aa Aa x Bb Bb ( Va + Vb k' )
Since k' = 0,
r = k x Aa Aa x Bb Bb ( Va )
where, Aa = activity coefficient of HNO3 in acid layer.
Bb = activity coefficient of toluene in nitration product

From graph Aa = 150,
Bb = 1.
And,
x Aa = 0.0017
x Bb = 0.0098
Density of Acid Layer: ()AL = 1506.4 kg/m3

Density of Nitration Product: ()NP = 1146.9 kg/m3
Volume of the acid layer: (V)AL = 10524/1506.4 = 6.98624 m3/hr
= 6986.24 lt/hr
Volume of the nitration product: (V)NP = 1133.874/1146.9 = 0.98863 m3/hr
= 988.63 lt/hr
Total Volume = VTotal = (V)AL + (V)NP
= 6986.24 + 988.63 = 7974.87 lt/hr
53
Now, Va = (V)AL / VTotal = 6986.24 / 7974.87

= 0.876
In equation (1);
r = 110.39 x 0.0017 x 0.0098 x 150 x 1 x 0.876
r = 0.24166 gmol / lt hr.

Toluene feed rate = FAO = 8.1998 kgmol/hr
Therefore Volume of the Reactor:
VR = FAO (XAf XAO) / (-r)

= 8.1998 (0.97 0) / 0.24166
VR = 33 m3
54
2. MECHANICAL DESIGN OF REACTOR:

Volume of the reactor = V = 33 m3
Assuming L/D = 3
V = (D2/4) x L = (/4) x 3(D)3
Diameter, D = (4V/3)1/3 = [4 x 33 / (3 x )] = 2.4 m
Height, L = 33/( x 2.42/4) = 7.3 m
(Ref. 8,10,11)
Turbine Agitator Design:
We use 6 blade turbine agitator .The diameter of impeller varies from 30 to 50 %
of tank diameter.
Assuming that turbine operates at 200 rpm .
Diameter of reactor = 2.4 m
Diameter of agitator = 0.34 x 2.4
= 0.816 m
i.e using 34% of diameter of reactor as impeller diameter.
Density of mixed acid and mononitrotoluene, =1461.66 kg/m3
Viscosity of mixture, = 4 cP
NRe = Nda2/ = [1461.66 x 200/60 x (0.816)2] / 4 x 10-3 = 811045.9 > 10,000
From M.V. Joshi, Process Equipment Design, 2nd edition
From power curve, Np = 6.1 for Reynolds number greater than 10,000
From equation 14.1
Power, P = NP N3 Da5/(gc x 75)
= (6.1 x 1461.66 x (200/60)3)x (0.816)5 ) / (9.81 x 75)
= 162.38 hp
Gland losses (10%) = 16.238 hp
Power input = 162.38 + 16.238 = 178.62 hp
Transmission system losses (20%) = 178.62 x 0.2
55
= 35.724 hp
Total hp = 178.62 + 35.724 = 214.344 hp
This will be taken as 220 hp to allow for fitting losses
It is advisable to use 220 hp motor.
Shaft design
Continuous average rated torque on the agitator shaft,

Tc= (hp x 75 x 60)/ (2 N)
= (220 x 75 x 60)/ (2 x 200)
= 787.82 Kg m
Polar modulus of the shaft cross section is,

Zp = Tm/fs
Where Tm is maximum torque = 1.5Tc = 1181.73 kg m
fs shear stress 550 kg/cm2
Zp =(1.5 x 787.82 x 100) /550
= 214.86 cm3
d3/16 = 214.86
d = 10.3 cm
Torque Tm is resisted by force Fm acting at a radius of 0.75Rb from the axis of agitator
shaft.
Where Rb is radius of blade.
Force, Fm = Tm/0.75Rb
Fm = (1.5 x 787.82 x 100) / (0.75 x 25)
= 6302.6 kg
Maximum bending momentum

M = Fm x l
Where l is length of overhang of agitator shaft between bearing and agitator.
Let l= 1500mm
56
M = 6302.6 x 1.5 = 9453.9 Kg-m

Equivalent bending moment
Me =
1
2
2
M + M + Tm
= [ 9453.9 + (9453.92 +1181.732)1/2]

= 9490.7 Kg-m
The stress due to equivalent bending

F = Me/Z
Z = (10.3)3/32
(Modulus of section of the shaft cross section)
Z = 107.3 cm3
f = (9490.7 x 100)/107.3
= 8845 kg/cm2
Stress f is higher than the permissible elastic limit (2560 Kg/Cm2). Therefore use
a 16 cm diameter shaft for which the stress will be,
f = 2360 Kg/cm2
Deflection of shaft
= (Wl3) /(3 EI)
[W = Fm]
Where E is the modulus of elasticity = 19.5 x 105 Kg/cm2

= [6302.6 (150)3 ]/[3 x 19.5 x 105 x ( x 164 )/64]
= 1.13 cm
Critical speed , Nc = (4.987 x 60) /
= 282 rpm
Since actual shaft speed is 200 rpm which is 71% of the critical speed. Therefore it is
necessary to increase the value of critical speed by decreasing the deflection.
Choose therefore 17cm diameter shaft.
Then,
= 0.887 cm
And Nc = 60 x 4.987/ 0.887 = 338 rpm
57
Actual speed is 60% of the critical speed

Blade design
Using blade width, W = 75mm
Blade thickness, t
= 8mm
Number of blades
=6
Stress in the blade, F
=(maximum torque)/(tw 2 /n)

=(10.74*10)/(0.8 x 7.52/6)
= 143 Kg/cm2
The value of stress is well within the limit for carbon steel.
Hub and key design

Hub diameter of agitator = 2 x shaft diameter
= 2 x 17
= 34 cm
Length of the hub = 1.5 x shaft diameter = 34 cm
Length of key = 1.5 x shaft diameter
= 34 cm
Tmax/(d/2)= lbfs = (lt/2)fc = (1181.73 x 100)/(17/2)

fs- shear stress in key (for carbon steel it is = 650 kg/cm2)
fc stress in crushing of key(for carbon steel it is = 1300 kg/cm2)
34 x b x 650 = 34 x t/2 x 1300 = 13902.7
on solving,
b = 6 mm
t = 6 mm
Use 6mm x 6mm x 34 cm key
Stuffing box and gland

Internal pressure = 1.1*10 5 Pa
= 1.2 kg/cm2
Internal diameter of stuffing box (in cm)
B = d+d
= 17 + 17 = 21.12 cm
58
Thickness of stuffing box in mm, t = PB/2f + C

Permissible stress in the material of stuffing box, f = 950 kg/ cm2
t = (1.12 x 21.12 x 10) /(2 x 950) + 17
= 17.12 mm
Load on gland,
F = (/4) p(b2 d2)
= (/4)(21.122 172)1.12
= 138 Kg
Size of the stud
F = (do2/4) nf
n is the no of studs = 4
f is the permissible stress for stud = 587 Kg/cm2
d02 = 0.0748 cm
d0 = 0.27 cm
But minimum stud diameter of 15 mm should be provided.
Stud diameter = 15 mm
Flange thickness = 1.75 x d
= 1.75 x 15 = 27mm
Coupling: A clamp coupling of cast iron is used

Force per bolt = 2 Tmax/(d (n/2))
No of bolts, n= 8 (for shaft diameter of greater than 5cm)
- Coefficient of friction = 0.25
Force per bolt= (2 x 1181.73 x 100) / ( x 0.25 x 17 x (8/2))
= 4425.36 kg
Area of bolt = (force on bolt)/(shear stress on bolt)
=4425.36/587
= 7.5 cm2
Diameter of bolt= (7.5 x 4)/
= 9.5 cm
59
Overall diameter of coupling = 2 x shaft diameter

= 2 x 17
= 34 cm
Thickness of reactor vessel
Allowable stress value, f = 1130 kg/cm2 (upto 1500 C for carbon steel)
Thickness of reactor, t
= (PD)/[(2fj)-P]
Where
j is joint efficiency
= 0.85
P is the design pressure

P = 1.1 Pactual
= 1.1 x 1.05
= 1.156 kg/cm2
t = (1.156 x 2400)/[(2 x 1130 x 0.85)-1.156]
= 4.5 mm with corrosion allowance

Thickness of reactor vessel = t = 6 mm
Design of reactor head

Using Flat head
Thickness of head, t = (CD/10) x ((P/f))
Where C is taken as 0.5
(from table 3.27, IS 2825 1969)
t = (0.5 x 2400/10) x ( 1.156 x 100/1130)0.5
= 38 mm
= 40 mm with 2mm allowance for corrosion.
60
Conical bottom thickness

Th =PD /( 2 x f x J x (cos )
Where
= 600 / 2
= 300
Th = 1.156 x 2400 / (2 x 1130 x 0.85 x cos30) + C
= 1.7 + 3
= 4.7 mm with corrosion allowance.
Nozzle diameter for Toluene inlet:

Feed rate of toluene
= 762 Kg/hr.
= 0.212 Kg/s
Assuming velocity, v1 = 0.01 m/s

Area of nozzle = mt /( v1 x 1)
Where mt is mass flow rate of toluene
v1 is the velocity of toluene
1 is density of toluene = 884.5 kg/m3
Area of the nozzle, A = 0.212 /( 0.01 x 884.5)
= 0.024 m2
Diameter of Nozzle = [(0.024 x 4 ) / ]1/2
Dn
= 17.5 cm (using diameter of 45 cm)
Thickness of the nozzle

Th = PDn / (2Fj-P)
= 1.156 x 450/[( 2 x 1130 x 0.85) 1.156]
61
= 0.27 + 3 mm = 3.27 mm
Nitrating acid mixture inlet nozzle Diameter:
Mass flow rate of acid mixture:
mam = 10903.5 kg/hr = 3.03 kg/s
Velocity, v1 = 0.01 m/s assuming
Density of mixture, = 1520.6 Kg/m3
Area of nozzle
= mam / ( v1)
= 3.03 / 1520.6 x 0.01
= 0.199 m2
Diameter of nozzle = (0.199 x 4 / )1/2

Dw = 50 cm
Thickness of the nozzle

Th =PDw / (2fJ-P) + C
=1.156 x 500 / (2 x 0.85 x 1130 1.156) + C
= 0.3 + 3
= 3.3 mm
Support Design
Bracket or lug support for a reactor:
Diameter of reactor = 2.4 m
Height of reactor = 7.3 m
Assuming, Clearance from vessel bottom to foundation = 1 m
Wind pressure = 128.5 kg/cm2
Number of Brackets to be provided for reactor of diameter 2.4 m, nb = 4 numbers.
62
Diameter of anchor belt circle

(from table 13.2, M.V. Joshi, 2nd edition) = 2.65 m
Height of bracket from foundation = 2.25 m (assuming)
Permissible stresses for structural steel
(IS 800) Tension = 1400 Kg / cm2
Compression = 1238 Kg/cm2
Bending = 1575 Kg/cm2
Permissible bearing pressure for concrete = 35 Kg/cm2
Calculation of weight of reactor vessel with its content:
Length of reactor = 7.3 m
Outside diameter of reactor = 2.412 m
Inner diameter of reactor = 2.4 m
Density of structure steel = 7880 kg/m3
Weight of reactor vessel,

W1 = 7880 x /4 (2.4122 2.42) x 7.3
= 2609 Kg.
Weight of tolune + Mixed acid,

W2 = /4 (Di2) l
= /4 x 2.42 x 7.3 x 1462
= 43860 Kg
Weight of the head
W3 = t x l x b x
63
= 40 x 10-3 x 2.4 x 2.4 x 7880 = 1816 Kg

Weight of 4 nozzles
W4 = 100 Kg.
Total weight W = W1+ W2 + W3 + W4
= 48385 Kg
Design weight = 1.3 x 48385
= 62900 Kg.
Load due to wind pressure

Wind pressure, Pw = k p h Do
where, k-Coefficient depending on the shape factor = 0.7
h is the height of reactor vessel = 7.3 m
p is given wind pressure =128.5kg/cm2
Do is the outside diameter of vessel = 2.412 m
Pw = 0.7 x 128.5 x 7.3 x 2.412 = 1583.8 Kg.
Maximum total compressive load in the support is

P = 4Pw (H F) + W
nDb
n
H Height of the vessel above the foundation
F Vessel clearance from foundation to vessel bottom.
W Maximum weight of the vessel
n = number of brackets = 4
Db = Diameter of bolt circle = 2.65 m
P = 4 x 1583.8 x (7.3 1) + 48385
4 x 2.65
4
64
= 15862 kg
Bracket:
(a)Base plate:
Suitable base plate size, a = 140 mm
B = 150 mm
Average pressure on the plate, Pav = P/(aB)
Pav= (15862)/(14x15)
=75.5 kg/cm2
Maximum stress in a rectangular plate subjected to a pressure Pav and fixed at the edges is
given by
f = 0.7 Pav (B2/T2) [ a2 / (B2 + a2)]
f = 0.7 x 75.5 x (152/T2) x [ 142 / (152 + 142) ]
= 5536/T2
For structural steel value of f =1575 kg/cm2
T12 = 5536 x 100 / 1575
T1 = 18.7 mm
Using 19 mm thick plate.
(b) Web plate.
Bending moment of each plate = (P/2) x (Db D)/2 x 100
= (15862/2) x (2.65 2.4)/2 x 100
= 99137 kg cm
Stress at the edge, f = (bending moment of each plate)/(T2 x a x a x 0.707)

Where T2 is web plate thickness
f = 99137/(T2 x 14 x 14 x 0.707)
= 715.4/T2
f = 1575 kg/cm2 for structural steel
Therefore T2 = 715.4/1575
65
= 4.5 mm
Column support for bracket:
It is proposed to use a channel section as column.
The size chosen is ISMC 150.
Size 150 x 75
Area of cross section 20 .88 cm2
Modulus of section, z 19.4 cm3
Radius of gyration, r 2.21 cm
Weight 16.4 kg/m
Height from foundation l- 2.25 m
Equivalent length for fixed ends le =1/2
= 2.25/2
= 1.125 m
Slenderness ratio = le/r
= 1.125 x 100 / 2.21 = 51
For the load acting eccentric on a short column, the maximum combined bending and
direct stress is given by,
f = W/An + We/nz
where,
w = Load on column
A area of cross section
e eccentricity
z modulus of section of cross section
n number of columns = 1
f = 15862/20.88 + (15862 x 7.5)/19.4

= 6890 kg/cm2
The calculated value of f is less than the permissible compressive stress and hence the
Channel selected is correct.
66
Base plate for column:

Size of the column 150 x 75
It is assumed that the base plate extends 25 mm on either side of channel
Side B 0.8 x 75 + 2 x 25 =110mm
Side C 0.95 x 150 + 2 x 25 = 192.5 mm
Bearing pressure, Pb = (p/4) x (1/(BC))
= (15862/4) x (1/(11x19.25))
= 18.73 kg/cm2
This is less than the permissible bearing pressure for concrete.
Stress is the plate,
f = (Pb/2) x h2 / (t2/6)
f = (6 x 18.73 x 2.52 )/(2t2)
but f = 1575 Kg/cm2

t2 = 351.2/1575
and t = 4.7 mm. It is usual to select a plate 4 to 6 mm thick.
67
(B) DESIGN OF CONDENSER:

1. PROCESS DESIGN OF CONDENSER:
Here the design of a Vertical Condenser is carried out.
Inlet temperature of cooling water = 24 C
Outlet temperature of cooling water = 40 C
Condensing Temperature = TC = 230 C
Mononitrotoluene to be condensed, m = 25 tons/day
= 1041.67 Kg/hr
= 0.2894 Kg/s
Here condensing temperature is assumed to be 230 C i.e the average boiling pont of
MNT, since 100% composition of MNT is obtained from the batch still as distillate.
Latent heat of vaporization of MNT = MNT = 4.6 x 107 J/Kmol
= 335.766 KJ/Kg
(Ref 6)
(A)
Preliminary Calculations:
(a) Heat Balance:
Qw = QMNT
mw Cpw ( T)w = mMNT MNT
mw = 0.2894 x 335.766 x103 = 1.45 Kg/s

4.187 x 103 x (40 24)
Q = (m)MNT = 0.2894 x 335.766 x 103 = 95827.73 W
(b) LMTD Calculations:

LMTD = (T1- t2) (T2 - t1) / ln [(T1- t2 )/(T2 - t1)]
LMTD =
(230 24) (230 40)

= 197.89 C
ln { (230 24) / (230 40)}
68
(B)
Routing of Fluids:
Shell side --- Condensing vapors of Mononitrotoluene
Tube side --- Cooling water
(C)
Heat Transfer Area:

Assume (Uo)d = 200 W/m2K
A =
Q
U x (LMTD)
95827.73
200 x 197.89
= 2.4212 m2
Using 5/8 inch OD, BWG tubes:

OD = do = 0.015875 m
ID = di = 0.012573 m
Heat Transfer area = a = do = x 0.015875 = 0.04987 m2/m length
Assume Length, L = 6ft = 1.8288 m
Allowing 50 mm thickness for tube sheet.
Heat transfer area for one tube = a1 = aL = 0.04987 x 1.7788 = 0.0887 m2/tube
Number of tubes, Nt = A/a1 = 2.4212 / 0.0887 = 28 tubes.
From Perry Hand Book; Table 11-3, for 5/8 inch OD, BWG tubes with 13/16
inch square pitch, TEMA - P or S:
Taking number of tubes = Nt = 48
Shell ID = 8 inch = 203 mm
Number of passes = Np = 2
Therefore,
(A)corrected = 48 x 0.0887 = 4.2576 m2
(Uo)d, corrected = 113.7 W/m2K
(D)
Film Transfer Coefficient:
Average temperature of water = [24 + 40] / 2 = 32 C

Wall temperature = Tw = [230 + (24 + 40)/2] / 2 = 131 C
Film temperature = Tf = [131 + 230] / 2 = 180.5 C
69
Shell Side:
Properties of MNT liquid at 180.5 C
Density = s = 1000 Kg/m3
Viscosity = s = 0.0005 Pa-s
Thermal conductivity = s = 0.11 W/mK
Specific heat = CPs = 266 KJ/mol-K
Re =
4W
=
4 x 0.2894
5 x 10-4 x 48 x x 0.015875
s Nt do
= 967.13
ho = 1.47 (32g/2)1/3 (Re)-1/3

ho = 1.47 x [ 0.113 x (103)2 x 9.81 / (5 x 10-4) ]1/3 x [ 967.13 ]-1/3 = 555.64 W/m2K
Tube side:
Properties of water at 32 C
Density = t = 995.026 kg/m3
Viscosity = t = 8.57 x10-4 Ns/m2
Thermal Conductivity = t =0.614 W/mK
Specific heat = CPt = 4.18 KJ/kg K
Total flow area: at = (Nt/Np) x di/4 = (48/2) x [ x (0.012573)2 / 4] = 0.0029797 m2
Gt = mw/at = 1.45 / 0.0029797 = 486.63 Kg/m2s
(Re)t = Gt di / t = 486.63 x 0.012573 / 0.0029797 = 7114.9
(Pr)t = tCPt/t = 8.57 x 10-4 x 4.18 x 103 / 0.614 = 5.83
hidi/t = 0.023 (Re)0.8 (Pr)0.4
hi = (0.614/0.012573) x 0.023 x (7114.9)0.8 (5.83)0.4 = 2744.5 W/m2K
Wall thickness, x = 0.015875 0.012573 = 3.3 x 10-3 m
w = 45 w/mK (for steel)
dw = [0.015875 + 0.012573] / 2 =0.014224 m
70
Dirt factor = 5.823 x 10-4 m/JsK

1 = 1 + do 1 + x do + dirt factor
(Uo)d
ho
di hi
w dw
=
1
+
(0.015875)
555.64 (0.012573 x 2744.5)
+ (3.3 x 10-3 x 0.015875) + 5.283 x 10-4

(45 x 0.014224)
(Uo)d,calculated = 357.6 W/m2K

This is acceptable.
(E)
Pressure Drop Calculations:
Shell side: (Kerns method)

Tvap = 230 C
Properties of MNT vapors at 230 C
vap = 4.1 kg/m3
vap = 0.022 W/mK
vap = 1.1 x 10-5 Pa-s
Shell side flow area:
as = (ID)s C1 B / PT
where C1 = 13/16 inch 5/8 inch = 3/16 inch = 4.7625 x 10-3 m
B = Baffle spacing = 0.203 m
PT = Pitch = 13/16 inch = 20.6375 x 10-3
as = 0.203 x 407625 x 10-3 x 0.203 / 20.6375 x 10-3 = 9.51 x 10-3 m2
Equivalent diameter = de = 4/(do) x [(PT)2 - (do)2/4]
= 4/( x 0.015875) x [(20.6375 x 10-3)2 - (/4) x (0.015875)2]
= 0.01828 m
71
Gs = ms / as = 0.2894 / 9.51 x 10-3 = 30.43 kg/m2s

(Re)s = Gs De / vap = 30.43 x 0.01828 / 1.1 x 10-5 = 50569
f = 1.87 (Re)-0.2 = 1.87 x (50569)-0.2 = 0.214
Nb + 1 = L/B = 1.8288/0.203 = 9
7P = [4 f (N + 1) D (G )
s
/ (2 De vap)] x (0.5)
= [4 x 0.214 x 9 x 0.203 x 30.432 / (2 x 0.01828 x 4.1)] x (0.5)

= 4830.55 N/m2
Tube side:
(Re)t = 7114.9
f = 0.079 (Re)-1/4 = 0.079 x (7114.9)-0.25 = 0.0086
7P
= 4 f L (Gt)2 / (2 di t) = 4 x 0.0086 x 1.8288 x (486.63)2 / [995.026 x 0.012573]

= 595.4 N/m2
7P = (2.5/2) x [(G ) / ] = (2.5/2) x (486.63)

t
7P
Total
7 7P )
= Np ( PL +
/ 995.026 = 297.5 N/m2
= 2 x (595.4 + 297.5) = 1785.8 N/m2
This is within the permissible pressure drop.
72
2. MECHANICAL DESIGN OF CONDENSER:

(a) Shell Side:
Material carbon steel (Corrosion allowance = 3mm)
Number of shells =1
Number of passes =2
Working pressure = 1 atm = 0.101 N/mm2
Design pressure = 1.1 x 0.101 = 0.11 N/mm2
Temperature of the inlet = 230 0C
Temperature of the outlet = 230 0C
Permissible Strength for Carbon steel = 95 N/mm2
b) Tube side:
Number of tubes = 48
Outside diameter = 15.875 mm
Inside diameter = 12.573 mm
Length = 1.8288 m
Feed =Water
Pitch,
re
= 13/16 inch = 0.0206 m
Working Pressure =1 atm = 0.101 N/ mm2

Design Pressure =0.11 N/mm2
Inlet temperature = 24 0C.
Outlet temperature = 40 0C
(Ref 7,8,10)
Shell Side:
ts = PDi
2fJ-P
ts = Shell thickness
73
P = design pressure =0.11 N/ mm2

Di = Inner diameter of shell = 0.203 m = 203 mm
f = Allowable stress value = 95 N/mm2
J = Joint factor = 0.85
ts =
0.11 x 0.203
(2 x 95 (0.85) 0.11)
= 0.138 mm
Minimum thickness = 6 + 3 = 9 mm (Including corrosion allowance)

ts = 10 mm
Head: (Torrispherical head)
th =
PRcW
2fJ
th = thickness of head
W = {3 + (Rc/Rk)1/2}
where, Rc = Crown radius = outer diameter of shell = 223mm
Rk = knuckle radius = 0.06 Rc
W = {3 + (Rc / 0.06 Rc)1/2 } = 1.77
th = 0.11 x 223 x 1.77

2 x 95x 0.85
= 0.27 mm
Minimum shell thickness should be = 10 mm (Ref .7)

th = 10mm
Since for the shell, there are no baffles, tie-nods & spacers are not required.
74
Flanges:
Loose type except lap-joint flange.
Design pressure (p) =0.11 N/mm2
Flange material : IS:2004 1962 class 2
Bolting steel : 5% Cr-Mo steel.
Gasket material = Asbestos composition
Shell side diameter =203mm
Shell side thickness =10mm
Outside diameter of shell = 203 + 10 x 2 = 223 mm
Determination of gasket width:

do =
di
y- pm
y-p(m+1)
where, y = Yield stress

m = gasket factor
Gasket material chosen is asbestos with a suitable binder for the operating conditions.
Gasket thickness = 10mm
m = 2.75
y = 2.60 x 9.81
= 25.5 N/mm2
1/2
do = 25.5 - 0.11 (2.75)

di
25.5 0.11 (2.75 +1)
= 1.002
Inside diameter of gasket

di = outside diameter of shell + 5 mm
= 223 + 5mm
= 228 mm
Outside diameter of the gasket
do = 1.002 (228) = 228.5 mm
75
Minimum gasket width = 228.5 - 228 = 0.25 mm

2
But minimum gasket width = 6mm
G = 228 + 2 x 6 = 240 mm (diameter at the location of gasket load reaction)
Estimation of bolt loads:
Load due to design pressure (H) = G2 P
4
H = (0.240)2 (0.11) = 4.98 x 10-3 MN
4
Load to keep the joint tight under operating conditions.
Hp = G (2b) m p
where, b= Gasket width = 6mm = 0.006m
Hp = (0.24) (2 x 0.006) x 2.75 x 0.11 = 2.737 x 10-3 MN
Total operating load (Wo) = H + Hp
= 7.717 x 10-3 MN
Load to seat gasket under bolt up condition = Wg

Wg = G b y
= x 0.24 x 0.006 x 25.5
Wg = 0.115 MN
Wg > W0
Wg is the controlling load

Controlling load = Wg = 0.115 MN
Calculation of minimum bolting area:
Minimum bolting area (Am) = Ag = Wg
Sg
where, Sg = Tensile strength of bolt material (MN/m2)
Consider , 5% Cr-Mo steel, as design material for bolt
76
At 230 0C
Sg = 138 x 10 6
N/m2 = 138 MN/m2
Am = 0.115 = 8.33 x 10-4 m2

138
Calculation for optimum bolt size:

g1 = go /0.707 = 1.415 go
where, gl = thickness of the hub at the back of the flange
go = thickness of the hub at the small end = 10 + 2.5 =12.5mm
Selecting bolt size: M18x2
R = Radial distance from bolt circle to the connection of hub & back of flange
R = 0.027 m
C = Bolt circle diameter = ID + 2 (1.415 go + R)
= 203 +2 (1.415 (12.5) + 27) = 292 mm
= 0.292 m
Actual flange outside diameter (A) = C + bolt diameter + 0.02
= 0.292 + 0.018 + 0.02
Check for gasket width:

Ab = minimum bolt area = 44 x 1.54 x 10-4 m2
Ab Sg = (44 x 1.54 x 10-4) 138
GN
x 0.24 x 0.012
= 43.35 N/mm2
2y = 2 x 25.5 = 51 N/mm2
A bS g
<
2y
GN
i.e., bolting condition is satisfied.
77
Flange Moment calculations :

(a) For operating conditions :
WQ = W1 +W2 +W3
W1 = B2 P = Hydrostatic end force on area inside of flange
4
W2 = H-W1
W3 = gasket load = WQ - H = Hp
B = outside shell diameter = 223 mm
W1 = (0.223)2 x 0.11 = 4.296 x 10-3 MN
4
W2 = H- W1 = (4.98 4.296) x 10-3 = 0.684 x 10-3 MN
W3 = Hp = 2.737 x 10-3 MN
Wo = (4.296 + 0.684 + 2.737) x 10-3 MN
= 7.717 x 10-3 MN
Mo = Total flange moment = W1 a1 + W2 a2 + W3 a3

where,
a1 = (C B)/2 ; a2 = (a1 + a3)/2 ;
a3 = (C - G)/
and C = 0.292 ; B = 0.223 ; G = 0.24

a1 = (0.292 0.223) / 2 = 0.0345
a3 = (0.292 0.24) / 2 = 0.026
a2 = (0.0345 + 0.026) / 2 = 0.03025
Mo = [4.296 (0.0345) + 0.684 (0.3025) + 2.737 (0.026)] x 10-3
= 0.24 x 10-3 MJ
(b) For bolting up condition:

Mg = Total bolting Moment = W a3
W = (Am +Ab)Sg/2
where, Am = 8.33 x 10-4
Ab = 44 x 1.54x 10-4 = 67.76 x 10-4
78
Sg = 138 MN
W = (8.33 x 10-4 + 67.76 x 10-4) x 138 = 0.525 MN
2
Mg = 0.525 x 0.026 = 0.01365 MJ
Mg > Mo
Mg is the moment under operating conditions

M = Mg = 0.01365 MJ
Calculation of the flange thickness:

t2 = (MCFY)/ (BSFO)
Now,
K = A = Flange diameter
= 0.246 = 1.103
B
Inner Shell diameter
0.223
K =1.103
Y = 15
Let CF = 1
SFO = Nominal design stresses for the flange material at design temperature.
SFO = 100 MN
M = 0.01365 MJ
B = 0.223 m.
t2 = (0.01365 x 1 x 17) / (0.223 x 100) = 0.0104 m2
t = 0.102 m
Bs = Bolt spacing = C = (0.292) = 0.0208 m
n
44
where, n = number of bolts = 44
CF = Bolt pitch correction factor
= [Bs / (2d + t)]1/2 = [0.0208 / (2 x 0.018 + 0.102)]1/2
= 0.388
CF = 0.623
79
t = 0.102 x 0.623 = 0.0635 m

Let us take t = 65 mm
Tube sheet thickness:
(Cylindrical Shell)
t1s = Gc KP / f
Where, Gc = mean gasket diameter for cover.
P = design pressure.
K = factor = 0.25 (when cover is bolted with full faced gasket)
F = permissible stress at design temperature.
t1s = 0.24 x [(0.25 x 0.11) / ( 95)]1/2 = 4.083 x 10-3 m = 4.083 mm
Considering corrosion allowance of 3 mm,

t1s = 8 mm
Channel and channel Cover:

th= Gc (KP/f)1/2
(K = 0.3 for ring type gasket)
= 0.24 x (0.3 x 0.11/ 95)1/2

= 4.47 x 10-3 m = 4.5 mm
Consider corrosion allowance = 3 mm.
th = 8 mm.
Saddle support:
Material: Low carbon steel
Total length of shell = 1.8288 m
Diameter of shell = 0.203 m
Knuckle radius = ro = 0.06 x 0.203 = 12.18 mm
Total depth of head (H) = (Doro/2)1/2
= (0.203 x 0.01218 /2)1/2
= 0.0356 m
80
Longitudinal Bending Moment:

Weight of the shell and its contents = W = 4753 kg
R = D/2 = 101.5 mm
Distance of saddle center line from shell end = A = 0.5R = 0.05075 m.
Q = (W/2)(L+4H/3)
= 4753 (1.8288 + 4 x 0.0356/3)/2
= 4459 kg m
M1 = QA[1-(1-A/L+(R2-H2)/(2AL))/(1+4H/(3L))]
M1 = 4459 x 0.05075
{1(1-0.05075/1.8288+(0.1015 -0.0356 )/(2x1.8288x0.05075))}

2
(1+4x0.0356/(3x1.8288))
= 1.11 kg-m
Bending moment at center of the span

M2 = QL/4[(1+2(R2-H2)/L)/(1+4H/(3L))-4A/L]
M2 = 1846.7 kg-m
Stresses in shell at the saddle
(a) At the topmost fibre of the cross section
f1 =M1/(k1 R2 t)
k1=k2=1
=1.11/( x 0.10152 x 0.01)
= 3430 kg/m2
The stresses are well within the permissible values.

Stress in the shell at mid point
f2 =M2/(k2 R2 t)
= 570.6 kg/cm2
Axial stress in the shell due to internal pressure
fp= PD/4t
= 0.11x 0.203 /( 4 x 0.01)
= 5.69 kg/cm2
f2 + fp = 576.29 kg/cm2
The sum f2 and fp is well within the permissible value.
81

MNT Design 2520of 2520equipments

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MNT Design 2520of 2520equipments

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Production of Mononitrotoluene

r = k xAa Aa xBb Bb (Va + Vbk )

x Aa = mole fraction of HNO3 in acid phase.

Aa = activity coefficient of HNO3 in acid layer.

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E cal per g-mole

A (rates in g-mole per hr per liter of combined phases )

= -14000 / (1.987 x ( 273 + 35 ) ) + 27.58

Kgmol/hr Weight % Mol %

Outlet from the reactor:

Kgmol/hr Weight % Mol %

Kgmol/hr Weight % Mol %

From equation (1),

Bb = activity coefficient of toluene in nitration product

Density of Acid Layer: ()AL = 1506.4 kg/m3

Now, Va = (V)AL / VTotal = 6986.24 / 7974.87

r = 0.24166 gmol / lt hr.

VR = FAO (XAf XAO) / (-r)

2. MECHANICAL DESIGN OF REACTOR:

Continuous average rated torque on the agitator shaft,

Polar modulus of the shaft cross section is,

Maximum bending momentum

M = 6302.6 x 1.5 = 9453.9 Kg-m

= [ 9453.9 + (9453.92 +1181.732)1/2]

The stress due to equivalent bending

(Modulus of section of the shaft cross section)

Where E is the modulus of elasticity = 19.5 x 105 Kg/cm2

Actual speed is 60% of the critical speed

Stress in the blade, F

=(maximum torque)/(tw 2 /n)

Hub and key design

Tmax/(d/2)= lbfs = (lt/2)fc = (1181.73 x 100)/(17/2)

Stuffing box and gland

Thickness of stuffing box in mm, t = PB/2f + C

Coupling: A clamp coupling of cast iron is used

Overall diameter of coupling = 2 x shaft diameter

P is the design pressure

= 4.5 mm with corrosion allowance

Design of reactor head

Conical bottom thickness

Nozzle diameter for Toluene inlet:

Assuming velocity, v1 = 0.01 m/s

= 17.5 cm (using diameter of 45 cm)

Thickness of the nozzle

Diameter of nozzle = (0.199 x 4 / )1/2

Thickness of the nozzle

Diameter of anchor belt circle

Weight of reactor vessel,

Weight of tolune + Mixed acid,

= 40 x 10-3 x 2.4 x 2.4 x 7880 = 1816 Kg

Load due to wind pressure

Do is the outside diameter of vessel = 2.412 m

Pw = 0.7 x 128.5 x 7.3 x 2.412 = 1583.8 Kg.

Maximum total compressive load in the support is

Stress at the edge, f = (bending moment of each plate)/(T2 x a x a x 0.707)

f = 15862/20.88 + (15862 x 7.5)/19.4

Base plate for column:

Stress is the plate,

but f = 1575 Kg/cm2

(B) DESIGN OF CONDENSER:

mw Cpw ( T)w = mMNT MNT

mw = 0.2894 x 335.766 x103 = 1.45 Kg/s

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